Genc Degirmen commissioned largest milling facility in Kazakhstan’s Kostanay region

Having completed more than 350 flour and semolina production facilities in 54 countries since 1990, Genc Degirmen continues its turnkey projects. Genc Degirmen has successfully commissioned a modern plant with a grinding capacity of 700 tons / day in Kazakhstan, one of the world’s important wheat producers and exporters.

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Genc Degirmen, one of the leading companies in milling technology, has completed nearly 54 turnkey projects in Kazakhstan and has built large silos, machinery and equipment for nearly 20 companies. The company provides solutions for the needs of the investor in the sales and service phase in Kazakhstan with two branches and provides them with high quality services and products.

Genc Degirmen completed another important project in Kostanay region, which is known as Kazakhstan’s wheat basket. Genc Degirmen has established a flour mill with a capacity of milling 700 tons / day in Kostanay, where important investments have been made in recent years in order to become an agricultural industrial center of Kazakhstan. The plant, established for Best Kostanay company, is designed with a total capacity of 700 tonnes per day. In this design, total capacity of dry wheat silos is 1,200 tonnes; the total capacity of wheat storage silos is 18,000 tonnes.

In a press release about the new plant, Turkish company said, “Investors, who promote Genc Degirmen with the latest technology in the industry and are jealous of maintenance time and costs that minimise operating costs, will be leaders in their region thanks to this state-of-the-art facility. With the full- capacity automation system, the investor saves work and costs. From an industrial point of view, these achievements show that 4.0 is not a far-sighted dream. Genc Degirmen has in this factory; Construction and positioning with the dedication of all specialists in the steel floor construction “Single Line” have been implemented seamlessly.”

A MODERN DESIGN WITH EXPANDABLE CAPACITY
Genc Degirmen has assured to make the preparations for the new mill with a grinding capacity of 700 tonnes/day in line with the negotiations in 2017 with the operation of Best Kostanay. So far, Best Kostanay has set the installation area and the operating requirements. Work in this area was completed with the common position of the two companies. The plant will be installed on a total area of 40,000m2 including green space applications, employee social space, parking areas and general administrative area. As part of this plan, a production area of 3000 m2, on which the main production area and the machines are located, will be produced in the desired types and specifications. The building design is expandable and the capacity can be increased to meet the needs of the country and the market in the future. With this design, the goal is to increase the capacity of feeder and storage silos and the desired flour production capacity by expanding the existing machinery.

The cleaning capacity of the system is 800 tonnes/day. The cleaning process begins with the spike separation process and the cleaning process continues with the FourClean F2 model. The stone separator and the light grain separator of the FourClean F2 model prevent empty, rotten and unhealthy wheat from entering the annealing and grinding process.

The quality of the flour is increased to the optimum level with the help of the machine. FourClean F2 model separates lighter particles; it is transferred to the waste department and, after processing, converted into various products and used as bait.This separation improves the flour white value, which plays an important role in the quality values of flour.

After all these processes, the products are classified according to their dimensions and the dampening process takes place partly with the help of Triexta and intensive dampener machines. After this phase, the products are sent to rest in the resting silos. The crushing operation is performed after the dampening, and the fracture separation is broken before the B1 bunker is removed. In the grinding area there are four double and 20 single Treximat Roller-Mills.

At the same time, Quantumox Sifter with a stainless-steel surface suitable for food safety are used for screening. The entire system is monitored by the central automation system and an automatic lubrication system is integrated for the grinding department. High efficiency electric motors have been chosen to reduce system energy consumption and increase environmental sensitivity.

INFRASTRUCTURE ALLOWS PRODUCT DIVERSITY
The macro and micro dosing and premixing system has been introduced and this facility has been presented to the investor by creating an infrastructure that allows for product diversification during full capacity operation. In this regard, the application of raw material dosing to by-products such as gluten-free bread, wholemeal bread, olive oil bread, etc. has been completed.

Kazakhstan ranks 12th in global wheat production and sixth in exports. Kazakhstan is the most important grain producer (especially wheat) in the Central Asian region. The region in which Best Kostanay operates is wheat basket of the country. The company usually buys wheat from its own domestic market. This situation has a positive effect on the costs of delivering and transporting wheat. As a company already has an experienced in flour production, Best Kostanay also benefits from the region’s advantages in sourcing high-quality wheat.

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